Induksi PDF

GEN00126-01
HYDRAULIC PC490LC-11
EXCAVATOR
SERIAL NUMBERS 85001 and up
FOREWORD
3INCETHISMACHINEISLARGEINSIZEITISDIVIDEDINTOSOMEUNITSTOMEET
THETRANSPORTATIONCONDITIONSANDREGULATIONSAPPLIEDTOTHETRANSPORTA
TIONROUTEWHENSHIPPEDFROMOURFACTORY
4HIS MANUAL DESCRIBES HOW TO ASSEMBLE THE UNITS INTO THE COMPLETE
MACHINEINTHEFIELD7EHOPETHATTHISMACHINEWILLDISPLAYITSQUALITY
ANDYOUWILLUSEITSAFELYACCORDINGTOTHEOPERATIONMANUAL
-ANYUNITSARELARGEINSIZEANDHEAVYINWEIGHTANDMAYBEHANDLED
INADANGEROUSPLACEORPOSTUREANDMANYWORKERSMAYHAVETOWORK
TOGETHERTOSLINGTHEMWITHCRANES
!CCORDINGLYBEFORESTARTINGTHEASSEMBLYWORKTHEWORKSUPERVISORIS
REQUIREDTOHOLDASAFETYMEETINGTOOBLIGETHEWORKERSTOPUTONPRO
TECTIVEGEARANDAPPOINTAWORKLEADERANDACRANEWORKSIGNALMAN
ANDALLOTROLESTOALLTHEWORKERSFORSAFEWORK
)NPARTICULARTHEABOVEMEETINGISMOREIMPORTANTWHENWORKEROFDIF
FERENTLANGUAGESANDCUSTOMSWORKTOGETHER
4HEFOLLOWINGISAREFERENCESUPERVISIONSYSTEMDIAGRAM
(Instruction system)
Work leader
Director
Work supervisor Crane director and
deputy director
Operator for assembly

Liaison man
Mechanics Sharing of work

Interpreter
.OTETHATTHISMANUALDOESNOTDESCRIBETHEWHOLESPECIFICATIONOFTHE
MACHINEBUTDESCRIBESONLYTHEBASICSPECIFICATION
)FYOUHAVEANYQUESTIONWHENDIVIDINGANDTRANSPORTINGTHEMACHINE
BYYOURSELFINFUTUREASKONEOFOURDISTRIBUTORS
CONTENTS
Specifications ...................................................................................................................... 1
Precautions for field assembly ............................................................................................ 2
Disposal of removed parts................................................................................................... 3
Assembling procedures, applicable equipment and schedule ............................................ 4
Flow of field assembly ......................................................................................................... 5
Kit layout diagram................................................................................................................ 6
Transportation ..................................................................................................................... 7
Tool list for field assembly ................................................................................................... 10
Tightening torque ................................................................................................................ 11
Coating materials ................................................................................................................ 16
Selection of wire ropes used for assembly.......................................................................... 20
Selection of nylon slings used for assembly........................................................................ 21
A. Assembly of chassis ....................................................................................................... 23

A- 1. Installation of climbing step .................................................................................... 24
A- 2. Installation of handrail ............................................................................................ 26
A- 3. Installation of mirror................................................................................................ 28
A- 4. Installation of tail pipe, tail pipe cover..................................................................... 31
B. Assembling of work equipment ....................................................................................... 33

B- 1. Installation of boom cylinder................................................................................... 34
B- 2. Releasing remaining pressure in hydraulic circuit .................................................. 36
B- 3. Installation of boom cylinder hoses ........................................................................ 37
B- 4. Installation of boom cylinder top pin ....................................................................... 38
B- 5. Installation of boom assembly ................................................................................ 39
B- 6. Installation of hoses from chassis along top of boom............................................. 43
B- 7. Connection of boom cylinder head......................................................................... 44
B- 8. Installation of arm assembly................................................................................... 45
B- 9. Installation of bucket cylinder hoses between boom and bucket cylinder .............. 47
B-10. Installation of bucket.............................................................................................. 49
B-11. Connection of work equipment grease piping ....................................................... 52
B-12. Connection of work equipment wiring ................................................................... 54
B-13. Greasing after completion of work equipment....................................................... 56
B-14. Bleeding air from work equipment circuit .............................................................. 57
C. Increasing and decreasing of track frame gauge, assembling of counterweight ............ 59

C- 1. Increasing and decreasing of track frame gauge ................................................... 60
C- 2. Installation of steps ................................................................................................ 66
C- 3. Installation of travel piping covers ......................................................................... 67
C- 4. Adjustment of track tension ................................................................................... 71
C- 5. Sticking sheet to counterweight ............................................................................. 74
C- 6. Installation of camera ............................................................................................. 75
C- 7. Installation of counterweight................................................................................... 81
M. Procedure for inspection and maintenance after completion of assembly ..................... 85

M- 1. Replacement of return filter (Standard filter to flushing filter) ................................ 86
M- 2. Flushing of hydraulic circuit ................................................................................... 87
M- 3. Replacement of return filter (Flushing filter to standard filter)................................ 86
M- 4. Check of oil/coolant level at each part ................................................................... 91
M- 5. Inspection of oil level in hydraulic tank and refill.................................................... 93
M- 6. Parts to be touched up after field assembly........................................................... 95
M- 7. Error code .............................................................................................................. 96
Mounting bolt torque check sheet

Field assembly inspection report (Backhoe)
Specifications
Machine model PC490LC-11
Weight of machine kg 47,040
Bucket capacity m3 1.9
Engine model — KOMATSU SAA6D125E-7
Flywheel SAE J1995 (Gross) 270/1,900{362/1,900}
kW/min-1 {HP/rpm}
horsepower ISO 9249/SAE J1349 (Net) 268/1,900{359/1,900}
Min. ground clearance mm 700
Travel speed (Low/High) km/h 3.0/4.2/5.5
Swing speed rpm 9.1
PC490LC-11
1
Precautions for field assembly
1. Selection of work place
1) When selecting a work place, consider the following.
• Is the work place sufficiently wide for loading and unloading the machine? (See the kit layout drawing.)
• Is the ground sufficiently hard? (The machine and crane truck must not sink into the ground.)
• Is the ground flat? (The ground surface must not be uneven or sloping.)
• Is the road to inlet/outlet of the work place sufficient for turning the trailer and crane truck?
2) Take care extremely that dirt or water will not enter the hydraulic circuit while it is assembled.
3) Avoid working outdoors while strong wind is blowing or it is raining.
4) Take measures to protect the machine from sand, dirt and rainwater while the work is stopped.
2. How to do work
The work supervisor or the work leader should not do the work while reading this manual but should read and
understand this manual thoroughly and then start the work.
In particular, write the "Precautions" for each work process in a sheet to explain or stick that sheet to the work
place so that all the workers will observe the precautions.
3. Preparation and check of protective gear, slings and tools

The work supervisor or the work leader must perform the following checks about protective gear, slings and
tools.
1) Are all the workers wearing helmets and other protective gear which they are obliged to wear? If special
protective gear is necessary, check that it is prepared and can be used without problem.
2) Are all the slings and tools prepared? Check in advance that they are ready to be used without problem.
In particular, check wooden blocks for internal decay and cracking.
4. k Check during actual work

The work supervisor or the work leader must check the following items constantly and make all the workers ob-
serve them.
1) Are the parking brakes of the trailer and crane truck applied securely and are their wheels locked with
chocks during work? Are outriggers, if installed, used securely?
2) Are the temperature and pressure of the engine, hydraulic oil, coolant, etc. lowered sufficiently during work?
3) Is horn or another signal is made to warn around when the engine is started? In addition, is it checked that
work equipment control lever and other control levers are in neutral and the fuel control dial (or fuel control
lever) is in the low idle position?
4) Is the balance of the slung item checked extremely during sling work with the crane?
5) Is entry prohibition for outsiders to the work place observed?
5. The work supervisor or the work leader is required to hold a meeting with all the workers at the beginning of
every morning and explain the work plan of the day to them and give them instructions to observe the safe
work.
2
Disposal of removed parts
As described in "FOREWORD", when this machine is transported, it is divided into some units such as the body,
undercarriage, cab, work equipment, etc. according to the transportation measure, regulations,etc.
Accordingly, the hydraulic pipings and hydraulic hoses to connect the units, oil inlets and outlets of the hydraulic
devices, and parts which must not be damaged are plugged or covered to prevent oil leakage, entry of dirt and
dust, and damage during transportation.
In addition, fixing jigs are used to prevent a trouble caused by a fall or a shake during transportation and to facilitate
loading, unloading and crane work.
The above plugs, jigs, etc. are removed when the machine is assembled and become unnecessary after comple-
tion of the machine. Since they are useful when the machine needs to be transported in future, however, we rec-
ommend you to keep them as long as possible.
3
Days
Backhoe · Inspection of oil level and

coolant level
· Air bleeding from work
equipment cylinder 3 Division
· Flushing of hydraulic
Assembly unit circuit
· Adjustment of track
Unloading parts Assembly of work Increasing of track Installation of tension
Step equipment frame gauge counterweight · Performance test
Handrail and mirror
Assembling procedures,
Crane
45t
4
applicable equipment and schedule
Air compressor
Worker
Leader + 3 mechanics
Start of assembling
· Completion of general
· Meeting with all workers assembling
Flow of field assembly
*1 Installation of accessories
*2 Installation of boom cylinder
*2•*3 Installation of boom
*2•*4 Installation of arm
*2 Installation of bucket
Greasing of work equipment
Air bleeding (work equipment)
Increasing of gauge
*5 Installation of sub
Installation of counterweight counterweight
*6 Installation of accessories
Flushing
Check of oil and coolant levels
– Completion inspection
Precautions
*1: Installation of grip, handrail, rear view mirror, tail pipe, and tail pipe cover
*2: Adjustment of shim
*3: Installation of working lamp
*4: Bucket cylinder and link are installed before shipment
*5: Installation of sound absorbing material, backup lamp, and rear view
monitoring camera
*6: Installation of track frame step and travel piping cover
5
Kit layout diagram
• The dimensions given below are the minimum dimensions needed.
• The kit dimensions in the diagram are outline dimensions.
• When selecting a place, see “Precautions for Field Assembly”.
6
Transportation
Packing Style for Transportation
These machines can be divided into three kits for transportation.

Please ask us or our service shop for transportation.
t 3-kit Transportation
(Upper structure + Undercarriage) (Work equipment) (Others)
t Packing Style of Each Kit (Sizes in drawing are given in millimeters.)

• Upper structure + Undercarriage
Model PC490LC-11
A (mm) 6,050
B (mm) 3,360
Shoe width 700
(mm)
Overall width
(mm) 3,150
Weight 28,930
(kg)
7
Packing Style of Each Kit (Sizes in drawing are given in millimeters.)
(1) Boom
Model PC490LC
A (mm) 7,290
B (mm) 1,725
Overall width 780
Position of center of gravity (mm)
Weight
(kg) 4,230
(2) Arm
Model PC490LC
A (mm) 4,610
B (mm) 955
Overall width
Position of center of gravity (mm) 675
Weight 2,210
(kg)
(3) Boom cylinder
Model PC490LC
Weight
(kg) 365
Position of center of gravity
8
(4) Bucket
Model PC490LC
A (mm) 1,839
B (mm) 1,499
Overall width 1,624
(mm)
Weight 1,366
(kg)
(5) Counterweight
850
3,000 Model PC490LC
Weight (kg) 9,570
1,165
9
Tool list for field assembly
No. Part name Specification Q'ty Remarks
1 Compressor 7.0kg/cm3 1
Equipment
2 Crane truck 25 ton 1

3 Grease pump Air supply set 1 For greasing work equipment
4 Stepladder 5-step, 1,500 mm 2
5 M10 bolt 1 Torque capacity: 30 – 170Nm
Small-sized impact wrench {3.06 – 17.3 kgf·m}
6 M12 bolt 1
Medium-sized impact Torque capacity: 200 – 700Nm
7 wrench M14 – M20 bolt 1 {20.4 – 71.4 kgf·m}
8 Large-sized impact M24 – M33 bolt 1 Torque capacity: 1,000 – 2,500Nm
wrench {102 – 255 kgf·m}
9 Air hose for impact wrench 50 m 1
10 Socket 22 mm width across flats 1
Medium-sized impact
11 wrench socket Socket 24 mm width across flats 1
Large-sized impact
14 wrench socket Socket 46 mm width across flats 1 Track frame connecting bolt
15 Socket 65 mm width across flats 1 Counterweight
4:1 torque multiplier
16 wrench 25.4, 19 1
T25.4 square x Width across flats 46 mm
Tool
17 Socket for 4:1 torque 1 each Track frame

18 multiplier wrench T25.4 square x Width across flats 65 mm 1 each Counterweight
19 42 kgm – T25.4 1 35 – 420Nm {3.57 – 42.8 kgf·m}
20 Torque wrench 85 kgm – T25.4 1 420 – 1,050Nm {42.8 – 107 kgf·m}
1,050 – 4,200Nm {107 – 428 kgf·m}
21 420 kgm – T38.1 1 Counterweight
1 set of
22 Standard tools Socket, spanner, ring wrench 2 each
23 Large hammer (plastic) 10 P 1
24 Bar 1m 2
Hydraulic jack For tightening track frame connecting
25 5 – 10 ton 1 bolts
26 Oil container Large and small ones 2 each For connecting travel piping and work
equipment piping
27 30 × 50 × 150 mm 2 Support of boom cylinder
Wooden block For tightening track frame connecting
28 400 × 200 mm 2 bolts
29 Wire ø10 × 3,000 mm 2
30 ø16 × 3,000 mm 2
31 ø20 × 5,000 mm 2 Boom, arm, bucket
32 ø30 × 3,000 mm 2 Counterweight
Sling
33 Shackle SD32 2 Rated load of 6 t for counterweight

34 SC18 4 Rated load of 2 t
35 Nylon sling 50 mm wide x 3,000 mm 2 Boom cylinder, arm cylinder
36 Lever block 1.5 – 3 ton 2 Increase of track frame gauge
37 Eyebolt M12 2
38 Cleaning liquid Brake cleaner spray can 10
Oil, grease, consumable
39 Hydraulic oil HO56-HE 200 l

40 Grease G2-LI 20 kg For greasing work equipment
41 Touchup paint Natural yellow spray can 5
42 Black gray spray can 5
43 Cloth 1 bundle 20 kg For cleaning
10
Tightening torque
1. Tightening torque for bolts
Tightening torque for bolts is indicated in the text as shown below. Tighten each bolt to the specified
torque.
Part No. of bolt TTTTT-TTTTT

Part No. of washer EEEEE-EEEEE
Bolt specification Thread size diameter
Thread (Diameter, pitch,
× Bolt length)
length
Tool (Socket) Applicable socket size
Tightening torque Nm {QQQ kgm}
If tightening torque for a bolt is not specified in the text, tighten it according to Table 1.
Remarks
1. The thread diameter is the nominal diameter. For example, 16 mm is expressed as M16 and 20
mm is expressed as M20.
The pitch in Table 1 is the distance that the bolt advances every turn in the axial direction (Unit:
mm).
2. The bolt length is dimension (c) in Fig. 1.
3. The applicable socket size is expressed as 24 mm, 30 mm, etc. Since 24 mm, 30 mm, etc. cor-
respond to dimension (b) in Fig. 1, an applicable socket can be selected from Table 1, too.
4. Tightening torque is expressed as QQQ – www or QQQ ± RR. If the target tightening torque
is set, expression of QQQ ± RR is applied.
Fig. 1
a : Bolt thread diameter (Nominal diameter)

b : Width across flats of bolt head
c : Bolt length
d : Threaded part of bolt
11
Table 1 Tightening torque for bolts not specified in text
Unit: Nm {kgm}
Nominal size of thread Width across flats Tightening torque

× pitch (= Socket size)
a (mm) b (mm) Target Range
12 8.8 – 14.7
M6 × 1 10
{1.2} {0.9 – 1.5}
25 14.7 – 34
M8 × 1.25 13
{2.5} {1.5 – 3.5}
54 34 – 74
M10 × 1.5 17
{5.5} {3.5 – 7.5}
89 54 – 123
M12 × 1.75 19
{9} {5.5 – 12.5}
137 84 – 196
M14 × 2 22
{14} {8.5 – 20}
230 147 – 309
M16 × 2 24
{23.5} {15 – 31.5}
315 201 – 427
M18 × 2.5 27
{32} {20.5 – 43.5}
460 319 – 608
M20 × 2.5 30
{47} {32.5 – 62}
650 471 – 829
M22 × 2.5 32
{66.5} {48 – 84.5}
810 588 – 1,030
M24 × 3 36
{82.5} {60 – 105}
1,180 883 – 1,470
M27 × 3 41
{120} {90 – 150}
1,520 1,130 – 1,910
M30 × 3 46
{155} {115 – 195}
1,960 1,470 – 2,450
M33 × 3 50
{200} {150 – 250}
2,450 1,860 – 3,040
M36 × 3 55
{250} {190 – 310}
2,940 2,260 – 3,630
M39 × 3 60
{300} {230 – 370}
a For symbols “a” and “b” in the table, see Fig. 1.
12
2. Tightening torque for pipe threads
Proper tightening torque for pipe threads depends on combination of the materials of the male screw and
female screw. In this manual, however, select tightening torque from Table 2 and Table 3 on the basis of the
material of the male screw. If tightening torque is specified specially in explanation, however, apply that tight-
ening torque.
2.1 If the male screw is made of mild steel or cast iron, apply Table 2.
Table 2
Unit: Nm {kgm}
Material of female thread
Steel Cast iron Light alloy
Nominal size (in)
3.9 – 6.9 2.9 – 5.9 2.0 – 3.9
1/8
{0.4 – 0.7} {0.3 – 0.6} {0.2 – 0.4}
5.9 – 11.8 4.9 – 9.8 3.9 – 7.8
1/4
{0.6 – 1.2} {0.5 – 1.0} {0.4 – 0.8}
16.7 – 26.5 13.7 – 21.6 9.8 – 16.7
3/8
{1.7 – 2.7} {1.4 – 2.2} {1.0 – 1.7}
32.3 – 52.9 26.5 – 43.1 19.6 – 32.3
1/2
{3.3 – 5.4} {2.7 – 4.4} {2.0 – 3.3}
51.0 – 85.3 42.1 – 70.6 31.4 – 52.9
3/4
{5.2 – 8.7} {4.3 – 7.2} {3.2 – 5.4}
86.2 – 173.5 72.5 – 146.0 54.9 – 111.7
1
{8.8 – 17.7} {7.4 – 14.9} {5.6 – 11.4}
2.2 If the male screw is made of refined steel (heat-treated hard steel), apply Table 3.
Table 3
Unit: Nm {kgm}
Material of female thread
Steel Cast iron Light alloy
Nominal size (in)
16.7 – 29.4 9.8 – 19.6 6.9 – 14.7
1/8
{1.7 – 3.0} {1.0 – 2.0} {0.7 – 1.5}
19.6 – 44.1 16.7 – 37.2 12.7 – 28.4
1/4
{2.0 – 4.5} {1.7 – 3.8} {1.3 – 2.9}
44.1 – 93.1 37.2 – 77.4 27.4 – 58.8
3/8
{4.5 – 9.5} 3.8 – 7.9} {2.8 – 6.0}
98.0 – 188.2 83.3 – 157.8 60.8 – 115.6
1/2
{10.0 – 19.2} {8.5 – 16.1} {6.2 – 11.8}
170.5 – 316.5 141.1 – 247.0 105.8 – 186.2
3/4
{17.4 – 32.3} {14.4 – 25.2} {10.8 – 19.0}
367.5 – 612.5 309.7 – 514.5 235.2 – 392.0
1
{37.5 – 62.5} {31.6 – 52.5} {24.0 – 40.0}
13
3. Tightening torque for hydraulic hose connecting nut
For the connecting nuts installed to the hydraulic hose adapters in relatively low pressure systems, apply
tightening torque in Table 4.1 and 4.2.
Table 4.1 Hydraulic hose of face seal type
Type that uses O-ring

at this position
(O-ring is fitted to joint
side)
Unit: Nm {kgm}
Outside diameter Tightening torque (Nm {kgm})
of hose Width across flats
(mm) Range Target
(mm)
Approx. 6 19 34 – 54 {3.5 – 5.5} 44 {4.5}
Approx. 10 22 54 – 93 {5.5 – 9.5} 74 {7.5}
Approx. 13 27 84 – 132 {8.5 – 13.5} 103 {10.5}
Approx. 16 32 128 – 186 {13.0 – 19.0} 157 {16.0}
Approx. 20 36 177 – 245 {18.0 – 25.0} 216 {22.0}
Table 4.2 Hydraulic hose of taper seal type
Type that does

not use O-ring
at this position
Unit: Nm {kgm}
Outside diameter Tightening torque (Nm {kgm})
of hose Width across flats
(mm) (mm) Range Target
Approx. 6 19 34 – 63 {3.5 – 6.5} 44 {4.5}
Approx. 10 24 59 – 98 {6.0 – 10.0} 78 {8.0}
Approx. 13 27 84 – 132 {8.5 – 13.5} 103 {10.5}
Approx. 16 32 128 – 186 {13.0 – 19.0} 157 {16.0}
Approx. 20 36 177 – 245 {18.0 – 25.0} 216 {22.0}
Note: When connecting hose, take care not to twist them.
14
4. Proper socket sizes for bolts of M39 and larger (Reference)
For the proper sizes of sockets or spanners (= width across flats) for tightening hexagon bolts of M39 and
larger, see Table 5.
Table 5
Unit: mm
Thread diameter Proper sizes of sockets or spanners
M42 65
M45 70
M48 75
M52 80
M56 85
M60 90
M64 95
15
Coating materials
a Select adhesives, liquid gaskets, greases, and other coating material used for disassembly and assembly
from the following list.
a If any coating is not shown in the following list, use the product shown in the manual or equivalent.
Shown
Category Komatsu code Part No. Q'ty Container Main features, uses in this
manual
LT-1A 790-129-9030 150 g Tube • Used to fix rubber gasket, rub-

ber cushion, or cork plug
• Used to glue resin (excluding
20 g polyethylene, polypropylene,
LT-1B 790-129-9050 (2- Polyethylene ethylene tetrafluoride, vinyl
container container chloride), rubber, metal, or non-
set) metallic material instantane-
ously firmly
• Features: Heat resistance and
Polyethylene chemical resistance
LT-2 09940-00030 50 g container • Used to lock bolts, plugs, etc.
and as sealant
790-129-9060 Adhesive: • Used to glue metal, glass, plas-
1 kg tic, etc. and as sealant
LT-3 Can
Set of adhesive Hardener:
and hardener 500g
Adhesive Polyethylene • Used to glue metal, glass, plas-
LT-4 790-129-9040 250 g tic, etc. and as sealant
container
HOLTS • Heat-resistant sealant for re-

790-129-9120 75 g Tube pairing engine
MH 705
• Instantaneous adhesive
Three bond Polyethylene • Adhesion time: 5 sec to 3 min
1735 790-129-9140 50 g container • Mainly used to glue metal, rub-
ber , plastic, and wood
• Instantaneous adhesive
Aron alpha Polyethylene • Quick-hardening type (Reach-
201 790-129-9130 2g container es max. strength 30 min after)
• Mainly used to glue rubber ,
plastic, and metal
• Features: Heat resistance and
LOCTITE Polyethylene chemical resistance
648-50 79A-129-9110 50 cc container • Used for gluing parts fitted at
high temperature
• Used as sealant for various
Polyethylene threaded portions, pipe joint,
LG-5 790-129-9080 1 kg container and flange
• Used as sealant for taper plug,
elbow, nipple, etc.
• Features: Silicon-based, heat
resistance, cold resistance
LG-6 790-129-9160 200 g Tube • Used as sealant for flange and
threaded portion
• Used as sealant for oil pan, fi-
Liquid gasket nal drive case, etc.
• Features: Silicon-based, quick-
hardening type
LG-7 790-129-9170 1 kg Tube • Used as sealant for flywheel
housing, intake manifold, oil
pan, thermostat housing, etc.
• Features: Silicon-based, heat
LG-8 resistance, vibration resist-
ThreeBond 419-15-18131 100 g Tube ance, impact resistance
1207B • Used as sealant for transfer
case etc.
16
Shown
manual
• Used to seal circle gear top
LG-9 which does not need to be
ThreeBond 790-129-9310 200 g Tube clamped and fill gaps of welded
1206D parts etc. having rough surfac-
es
• Can be painted
LG-10 • Used as lubricant and sealant
ThreeBond 790-129-9320 200 g Tube fro radiator hose
1206E • Can be painted
• Feature: Can be used with

LG-11 gasket
ThreeBond 790-129-9330 200 g Tube • Used for covers of transmis-
1121 sion case, steering case, etc.
ThreeBond • Liquid gasket for repairing en-
790-129-9090 100 g Tube gine
1121
• Used for press fitting, shrink fit-
ting, prevention of galling or
LM-P 09940-00040 200g Tube seizure of screw Q
• Used as lubricant for linkage,
bearing, etc.
Molybdenum • Spray type
disulfide • Thin molybdenum disulphide
lubricant film is formed on metal surfac-
– 09995-00250 190 g Can es to prevent galling between
metals
• Used for drive shaft spline,
needle bearing, various link
pins, bolts, etc.
• Feature: Compound consisting
of fine metal particles to pre-
vent seizure and galling
Anti-seize LC-G – – Can • Used for mounting bolts of
NEVER-SEEZ high-temperature parts such as
exhaust manifold, turbocharg-
er, etc.
SYG2-400LI • Multi-purpose extreme pres-
SYG2-350LI sure lithium grease
G2-LI
G0-LI(*) SYG2-400LI-A Various Various
*: For cold SYG2-160LI types types
weather SYG2-160CNLI
SYG0-400LI-A(*)
SYG0-16CNLI(*)
• Used for high-load portion
Grease
Caution: Do not use for rolling
LM-G(G2-M) bearings and splines such as
SYG2-400M 400g × 10
Molybdenum
disulfide SYG2-400M-A 400g × 20 Bellows can swing circle bearing Q
grease SYGA-16CNM 16 kg
• Apply to work equipment pins
only at assembly time and do
not use after that
17
Shown
manual
Hyper White • Has higher seizure resistance,
Grease SYG2-400T-A heat resistance, and water re-
G2-T SYG2-16CNT 400 g sistance than molybdenum di-
Bellows can sulphide grease
G0-T (*) SYG0-400T-A (*) 16 kg
*: For cold SYG0-16CNT (*) • Not conspicuous on machine
weather since color is white
Bio grease • Decomposed by bacteria in na-

G2B ture in short period to minimize
SYG2-400B effects on microorganism,
G2-BT (*) SYGA-16CNB 400 g
*: For high Bellows can plants, and animals
SYG0-400BT (*) 16 kg
temperature SYGA-16CNBT (*)
and high
load
• Feature: Silicon-based, wide
using temperature range, high
G2-S oxidation resistance, preven-
ThreeBond – 200 g Tube tion of deterioration of rubber
1855 and plastics
• Used as oil seal for transmis-
sion etc.
• Feature:Urea-based (organic)
grease having heat resistance
and long life. Sealed when
G2-U-SENS used.
427-12-11871 2 kg Can • Used for rubber in damper,
grease
bearing, oil seal
Caution:Do not mix with lithium
grease
SUNSTAR • Used as primer for cab
PAINT Glass side
PRIMER 580 20 ml container (Using limit: 4 months af-
SUPER ter date of manufacture)
417-926-3910
SUNSTAR • Used as primer for glass
GLASS Glass side (Using limit: 4
PRIMER 580 20 ml container months after date of man-
SUPER ufacture)
For gluing cab glass
• Used as paint primer for

SUNSTAR cab side
PAINT Glass
22M-54-27230 20 ml container (Using limit: 4 months af-
PRIMER 435-
Primer 95 ter date of manufacture)
• Used as primer for black

ceramic-coated surface
SUNSTAR on glass side and for hard
GLASS 22M-54-27240 polycarbonate-coated
PRIMER 435- 150 ml Steel can
surface
41 (Using limit: 4 months af-
ter date of manufacture)
SUNSTAR • Used as primer for sash
Glass (Almite)
SASH 22M-54-27250 20 ml container
PRIMER GP- (Using limit: 4 months af-
402 ter date of manufacture)
18
Shown
manual
• "S" is used for high-tem-
perature season (April to
SUNSTAR October) and "W" for low-
PENGUINE Polyethylene temperature season (Oc-
SEAL 580 417-926-3910 320 ml container tober to April) as adhe-
SUPER "S" or sive for glass
"W" (Using limit: 4 months af-
Adhesive • Used as adhesive for
Sika Japan, glass
Sikaflex 20Y-54-39850 310 ml Polyethylene
container (Using limit: 6 months af-
256HV
For gluing cab glass

Ecocart • Used as adhesive for
SUNSTAR glass
PENGUINE 22M-54-27210 320 ml (Special
container) (Using limit: 6 months af-
SUPER 560
SUNSTAR • Used to seal joints of
PENGUINE Polyethylene glass parts
417-926-3920 320 ml (Using limit: 4 months af-
SEAL No. container
2505 ter date of manufacture)
SEKISUI • Used to seal front window
Caulking Polyethylene (Using limit: 6 months af-
SILICONE 20Y-54-55130 333 ml container
material SEALANT ter date of manufacture)
• Used to seal joints of
GE TOSHIBA glass parts Translucent
SILICONES 22M-54-27220 333 ml Cartridge white seal
TOSSEAL (Using limit: 12 months af-
381
Natural yellow SYPA-U03SPNY – Spray type Q
Paint
Black gray SYPA-U03SPBG – Spray type Q
19
Selection of wire ropes used for assembly 18
Select wire ropes to be used for assembly according to the following table. B 8817-1991
Annex 2, Table 1 Using loads of 6 × 24 type rope slings.

Unit: kN {tf}
Number of wire ropes 1 pc. 2 pcs.
Sling angle   = 0°  Z 90° 90° <  Z 120°

Angle to vertical line   = 0°  Z 45° 45° <  Z 60°
Mode coefficient M 1 1.4 1
Classification of wire rope
Outer diameter of 24G 24A 24G 24A 24G 24A
wire rope (2)d (mm)
8 Max. 4.8 {0.49} Max. 5.2 {0.53} Max. 6.7 {0.68} Max. 7.2 {0.74} Max. 4.8 {0.49} Max. 5.2 {0.53}
9 Max. 6.1 {0.63} Max. 6.6 {0.67} Max. 8.5 {0.88} Max. 9.2 {0.93} Max. 6.1 {0.63} Max. 6.6 {0.67}
20
10 Max. 7.6 {0.77} Max. 8.2 {0.83} Max. 10 {1.0} Max. 11 {1.1} Max. 7.6 {0.77} Max. 8.2 {0.83}
11.2 Max. 9.5 {0.97} Max. 10 {1.0} Max. 13 {1.3} Max. 14 {1.4} Max. 9.5 {0.97} Max. 10 {1.1}
(12) Max. 10 {1.1} Max. 11 {1.2} Max. 14 {1.5} Max. 15 {1.6} Max. 10 {1.1} Max. 11 {1.2}
12.5 Max. 11 {1.2} Max. 12 {1.3} Max. 15 {1.6} Max. 16 {1.8} Max. 11 {1.2} Max. 12 {1.3}
14 Max. 14 {1.5} Max. 16 {1.6} Max. 19 {2.1} Max. 22 {2.2} Max. 14 {1.5} Max. 16 {1.6}
(24) Max. 43 {4.4} — Max. 60 {6.1} — Max. 43 {4.4} —
Selection of nylon slings used for assembly
Select wires used for assembly according to the following table
tRated load table (WW-1D type)
21
A. ASSEMBLY OF CHASSIS
23
Assembly procedure
Installation of climbing step (1/2)
A-1
For USA specifications

• Install step (1) with bolts (2).
No. Loose-supply items Q’ty

1 208-54-43140 1
2 01024-81225 4
Precautions Necessary tools Necessary equipment
Remove the rust preventive plug from the Name Q’ty Name Q’ty
tapped hole. Socket 19 mm width across flats 1
Small-sized impact wrench 1
Others
24
Assembly procedure
Installation of climbing step (2/2)
A-1
• Install grip (1) with bolts (2).

1 208-54-43150 1
2 01024-81230 2
Remove the rust preventive plug from the Name Q’ty Name Q’ty
tapped hole. Socket 19 mm width across flats 1
Others
25
Assembly procedure
Installation of handrail (1/2)
A-2
1. Set plate (2) and plate (4) at part Q, and then install handrail (1) with bolts (3).
a Weight of handrail: 21 kg

1 208-54-21921 1
2 208-54-43120 1
3 01024-81245 6
4 207-54-43851 1
a When carrying the handrail, use a crane Name Q’ty Name Q’ty
etc. Socket 19 mm width across flats 1
a Install the handrail to the right side of the
machine first, and then to the left side of
Medium-sized impact wrench 1
the machine.
When removing the handrail, remove
the left side of the machine first, then
remove the right side.
(Prevention of fall)
Others
26
Assembly procedure
Installation of handrail (2/2)
A-2
• Using bolts (3), install handrail (1) and plate (2) to the track frame.
a Weight of handrail: 12 kg

1 208-54-41833 1
2 208-54-43130 1
3 01024-81245 4
a When carrying the handrail, use a crane Name Q’ty Name Q’ty
etc. Socket 19 mm width across flats 1
a Install the handrail to the right side of the
machine first, and then to the left side of
the machine.
When removing the handrail, remove
the left side of the machine first, then
remove the right side.
(Prevention of fall)
Others
27
Assembly procedure
Installation of mirror (1/3)
A-3
(1) Install mirror (1).

Tightening torque of mirror mounting bolt: 6.0 to 7.0 Nm
{0.61 to 0.71 kgm}
View from right of machine
Adjust the mirror so that the operator in the operator

seat can see persons on the ground at 1 m around the
machine.
(W) : 1m

1 2A5-54-13420 1

Name Q’ty Name Q’ty
Hexagon socket 5 mm width 1
across flats
across flats
Others
28
Assembly procedure
A-3
(2) Install mirror (1).

Tightening torque of mirror(1) mounting bolt: 6.0 to 7.0 Nm
{0.61 to 0.71 kgm}

1 2A5-54-13420 1

across flats
Others
29
Assembly procedure
A-3
(3) Install mirror (1), support(2), and clamp(3).

Tightening torque of mirror(1) mounting bolt: 6.0 to 7.0 Nm
{0.61 to 0.71 kgm}

1 2A5-54-13420 1
2 2A5-54-16120 1
3 20Y-54-35430 1
4 01252-A1030 2

a Tighten bolts (4) according to torque table
1 (page 11). across flats
across flats
Others
30
Assembly procedure
Installation of tail pipe and tail pipe cover
A-4
(1) Install tail pipe.
Tightening torque: 11.8 Nm {1.2 kgm}
(2) Install tail pipe cover.
Adjust the cover to equalize the clearance marked with ※ .

1 208-01-21720 1
2 6253-11-515A 1
3 885-3353-911 1
4 208-54-21361 1
5 01034-81230 6

Others
31
B. ASSEMBLING OF WORK EQUIPMENT
• Clean the mounting pin and pin hole and check them for a flaw.
33
Assembly procedure
Installation of boom cylinder (1/2)
B-1
(1) Lift the boom cylinder and adjust it to the frame’s pin holes.
(2) Drive in the boom cylinder foot pin.
aInside of pin hole and bushing of boom cylinder boss: Apply LM-P (Only 1st time)
[Apply lithium grease for 2nd time and after]
(3) Check the clearance between the pin and chassis and combine and insert adjustment shims (1) so that the
clearance on the outside of the chassis will be 1.5 mm or less. Adjust the shims for both right and left cylinders.
Insert one piece of 207-70-71251 on the inside of the chassis and insert the other shims on the outside of the
chassis.
Outside of machine Inside of machine
Rest of shims 207-70-71251 1 piece

PART P
(Clearance must
be 1.5 mm or less)
(4) Push in the boom cylinder foot pin fully and install the lock plate.
a Check that the pin lock bolt is not loosened but tightened and check No. Loose-supply items Q’ty
207-70-71251 6
its torque. 1
207-70-71261 2
a Assemble so that the grease hole of the boom Name Q’ty Name Q’ty
cylinder bottom will be down. Nylon sling 2 25 t crane 1
a Decide the thickness of the adjustment shim
Socket 19 mm width across flats 1
by combining shims 1 mm thick (207-70-
71251) and 2 mm thick (207-70-71261). Small-sized impact wrench 1
a When pushing in the pin, take care not to break
the dust seal installed to the boom cylinder
boss.
Others
34
Assembly procedure
Installation of boom cylinder (2/2)
B-1
(5) Insert the boom cylinder supports between each cylinder and revolving frame.
* Wooden blocks 30 mm thick may be used instead of the cylinder supports.
Support stand
Boom cylinder
Revolving frame

Others
35
Assembly procedure
Releasing remaining pressure in hydraulic circuit
B-2
When removing the hydraulic piping, be sure to release the remaining pressure according to the following proce-
dure.
(1) Lower the work equipment lock lever to the "LOCK" position, and start and run the engine for about 10 seconds,
and then stop it.
a Limit the engine speed to low idling.
a Set the work equipment control lever in neutral.
(2) Within 15 seconds after stopping the engine, turn the starting switch to the ON position, set the lock lever to
the FREE position, and operate each control lever to the stroke end.
a Repeat the operations of (1) to (2) 3 times.
(3) Lower the lock lever to the "LOCK" position.
(4) Remove the oil filler cap of the hydraulic tank to release the pressure in the tank.
kWhen removing the oil filler cap of the hydraulic tank, turn it slowly to release the internal pressure first, and
then remove the cap carefully.
(5) After releasing the pressure in the tank, install the oil filler cap of the hydraulic tank to prevent entry of dirt.

Others
36
Assembly procedure
Installation of boom cylinder hoses
B-3
(1) Remove the oil stopper plug from the tube at the boom cylinder end.
(2) Set the new O-rings (3) to boom cylinder hoses (1) and (2), 4 pieces in total, and install them to the normal
circuit as shown in the figure below.
a Bleed the boom cylinder of air by following Assembly Procedure B-14 “Bleeding Air from Work Equipment
Circuit”.
a Check that the split flange is not loosened but tightened. No. Already installed to Q’ty
a Check that each O-ring is fitted, has not come off, and is not 1 207-62-52610 2
2 206-62-51650 2
caught.
3 07000-13032 4
1. When removing an oil stopper plug from a hose, Name Q’ty Name Q’ty
slowly loosen its bolts by gradually releasing the Oil container 2
internal hydraulic pressure.
2. Keep the removed oil plugs so that they can be Socket 14 mm width across flats 1
reused.
3. When connecting the hoses, take extremely Small-sized impact wrench 1
care not to clinch or damage the O-rings.
4. Also, take extremely care not to enter a foreign
material into the hydraulic circuit.
Others
37
Assembly procedure
Installation of boom cylinder top pin
B-4
Insert the boom cylinder top pin in the boom temporarily.

a Weight of boom cylinder top pin: 73 kg
a Apply LM-P to the inside of boss.

1 208-70-61860 1

Nylon sling 1 25 t crane 1
Others
38
Assembly procedure
Installation of boom assembly (1/4)
B-5
Removal of cover
1. Remove battery case small cover (1).
aWeight of battery case small cover: 1.72 kg
2. Open AdBlue/DEF cover.
3. Remove the fuel spray prevention cover.
4. Remove AdBlue/DEF cover.

aWeight of AdBlue/DEF cover: 34.98 kg
aWhen removing the cov-

er, take care not to hook M12 eyebolts may be
the breather in it. installed to 2 places to
install slings.
No. Parts installed to Q’ty

machine
1 208-54-21770 1
2 01024-81225 2
3 208-54-21881 1
4 01034-81225 4
5 01643-51232 4
6 208-54-21602 1
7 01024-81230 4

Socket, width across flats: 19 mm 1
Extension, L: 150 1
Others
39
Assembly procedure
B-5
5. Remove the fuel tank front cover.

a Weight of fuel tank: 9.87 kg
㪐㪏
6. Install the boom foot pin.

a When you install the boom foot pin, if the
mounting bolts of the filler port bracket and
breather bracket are obstacles, remove
and place them aside.
• Filler port bracket mounting bolt: (10), (11)

• Breather bracket mounting bolt: (12)
Install
If this is obstacle to installation

of boom foot pin, bent it
around rubber hose.
(Do not remove piping)
Rubber hose
No. Parts installed to Q’ty

machine
8 2A7-54-11742 1
7. After installing the boom foot pin, install the cover in the reverse order. 9 01024-81230 4
10 01024-81255 1
11 01024-81230 2
12 01024-81230 2

Extension, L: 150 1
Others
40
Assembly procedure
B-5
(1) Sling the boom assembly with the crane and match it with the pin holes of the machine.
a Protect the pin from the sling wires.
(2) Install the boom foot pin.
At this time, balance the boom so that it will be in parallel with the pin holes of the machine.
Weight of boom assembly : 4,230 kg

a When slinging boom assembly
(3) Check the clearance in the boom foot all around on the left
side of the chassis, then decide and insert the shim quantity
so that the minimum clearance will be 1 mm or less. (Clearance must be
The following adjustment shims are prepared. 1 mm or less)
(1) (208-70-71611, 3 pieces) t2.0
(2) (208-70-71621, 1 piece) t2.5
(3) (208-70-71631, 1 piece) t3.0
(4) (208-70-71641, 1 piece) t3.5
Assemble these shims to obtain desired thickness.
(Be sure to insert one of (1) on the right side of the machine.)
(4) Push in the boom foot pin fully and install the lock plate.
a Inside of pin hole and bushing of boom foot bushing: Apply
LM-P (Only 1st time) No. Loose-supply items Q’ty
1 208-70-71611 3
[Apply lithium grease for 2nd time and after] 2 208-70-71621 1
a Check that the pin lock bolt is not loosened but tightened 3 208-70-71631 1
and check its torque. 4 208-70-71641 1
a When pushing in the pin, take care not to break the Name Q’ty Name Q’ty
dust seal installed to the boom foot as shown below.
ø20 × 5,000 mm wire 2 25 t crane 1
Dust seals ø10 × 3,000 mm wire 1
Lever block 1.5 t 1
Large hammer 1
a For installation of the grease supply hoses, see Step
B-11 "Connesction of grease supply piping of work
equipment".
Others
a For the boom and boom cylinder assembly, see next

page.
41
Assembly procedure
B-5
a Installation of boom and boom cylinder assembly
(1) Sling the boom and boom cylinder assembly with the crane and match them with the pin holes of the chassis.
a Protect the pin from the sling wires.
(2) Install the boom foot pin.
At this time, balance the boom so that it will be in parallel with the pin holes of the machine
Weight of boom assembly : 4,950 kg

a When sling the boom
and cylinder assembly
(3) Decide and insert the shim quantity so that the clearance in
the boom foot on the left side of the machine will be 1 mm or
less.
The following adjustment shims are prepared. (Clearance must be
(1) (208-70-71611, 3 pieces) t2.0 1 mm or less)
(2) (208-70-71621, 1 piece) t2.5
(3) (208-70-71631, 1 piece) t3.0
(4) (208-70-71641, 1 piece) t3.5
Assemble these shims to obtain desired thickness.
(Be sure to insert one of (1) on the right side of the machine.)
(4) Push in the boom foot pin fully and install the lock plate.
a Inside of pin hole and bushing of boom foot bushing: Apply
LM-P (Only 1st time) No. Already installed to chassis Q’ty
1 208-70-71611 3
[Apply lithium grease for 2nd time and after] 2 208-70-71621 1
a Check that the pin lock bolt is not loosened but tightened 3 208-70-71631 1
and check its torque. 4 208-70-71641 1
a When pushing in the pin, take care not to Name Q’ty Name Q’ty
break the seals installed to the boom foot as ø20 × 5,000 mm wire 2 25 t crane 1
shown below
Dust seals ø10 × 3,000 mm wire 1
Lever block 1.5 t 1
Large hammer 1
a For installation of the grease supply hoses, see Step

Others

equipment".
42
Assembly procedure
Installation of hoses from chassis along top of boom
B-6
(1) Remove the oil stopping plugs of the tubes on the boom side.
(2) Install arm cylinder hoses (1), (2), (3), and

bucket cylinder hoses (4) (2 pcs.) to the regular circuit as shown below.
a Bleed the arm cylinder of air by following Assembly Procedure B-14

“Bleeding Air from Work Equipment Circuit”. No. Already installed to Q’ty
a Check that the split flange is not loosened but tightened. 1 208-62-41661 1
2 208-62-41671 1
a Check that each O-ring is fitted, has not come off, and is not caught. 3 208-62-41682 1
4 208-62-41642 2
5 07000-13032 5

1. When removing an oil stopper plug from a
hose, slowly loosen its bolts by gradually Oil container 2
releasing the internal hydraulic pressure.
2. Remove and store the flange, O-rings and Socket 14 mm width across flats 1
heads so that you can reuse them later.
3. When connecting the hoses, take extremely Small-sized impact wrench 1
care not to clinch or damage the O-rings.
4. Also, take extremely care not to enter a foreign
material into the hydraulic circuit.
Others
43
Assembly procedure
Connection of boom cylinder head
B-7
(1) Remove the stopper plate (2) fixed to the boom, and remove the boom cylinder top pin.
a Boom cylinder: 360 kg / Boom cylinder top pin: 73 kg
(2) Start the engine and rotate it at the low idle speed.
(3) Sling the right cylinder, raise the rod slowly, and match the pin holes while extending and retracting the cylinder.
(4) Knock in the cylinder top pin.
a Inside of pin hole and bushing of boom cylinder bushing: Apply LM-P (Only 1st time)
(5) Mount fixed the stopper plate and adjusting shims (5), (6).
0.5∼1.5mm
Clearance “a”
0.5∼1.5mm
Clearance “b” No. Loose-supply items Q’ty
1 208-70-61860 1
Part marked with A (2 points) 2 208-70-31242 2
3 207-70-13340 2
4 01580-12419 4
5 208-70-71561 4
6 208-70-71571 2

a When operating the cylinder, extend it slowly. Do not
operate the cylinder suddenly and do not operate it to
the end of its stroke. In the first operation, there is an Nylon sling 1 25 t crane 1
air in the cylinder and the cylinder may not move for
the first 10 seconds. In such case, do not operate the Socket 36 mm width across flats 1
control lever to the end of its stroke.
a Check the clearance between cover (2) and cylinder Spanner 36 mm width across flats 1
rod all around and combine shims 1 mm thick (208-
70-71561) and 2 mm thick (208-70-71571) so that Large-sized impact wrench 1
clearance "a" will be 0.5 – 1.5 mm. (Portions of )
a Adjust clearance "b" between the plate and double
nut to 0.5 to 1.5 mm.
(Part marked with A )
a Before operating the cylinder, check that the flushing
filter is installed (to capture dirt in the circuit).
a
Others
For installation of the grease supply hoses, see Step

equipment".
44
Assembly procedure
Installation of arm assembly (1/2)
B-8
(1) Remove lock plate (2) of boom top pin (1) fixed to the boom and pull out top pin (1).
(Boom top pin: 54 kg)
(2) Raise the arm assembly, align the position with the boom hole, insert a shim, then push in the pin.
(Arm assembly: For the weight, see the table in "Transportation")
a Seals (07145-00120 × 2) are installed to the inside of the bushing at the arm end, but be careful no to dam-
age the seals when inserting the pin.
a Inside of pin hole and bushing of arm bushing: Apply LM-P (Only 1st time)
a Check the clearance all around and combine shims (5), (6), and (7) so that the clearance will be 1 mm or
less (Portion of ).
(3) Install the stopper (2).
Shim thickness
(5) 208-70-71531 2.0 mm
(6) 208-70-71541 2.5 mm
(7) 208-70-71551 3.0 mm

1 208-70-71580 1
2 208-70-71670 1
3 01010-82045 2
4 01643-32060 2
5 208-70-71531 3
a Check that the pin lock bolt is not loosened but tightened and 6 208-70-71541 1
7 208-70-71551 1
check its torque.
a When pushing in the pin, take care not to break Name Q’ty Name Q’ty
the dust seal installed to the arm boss as Nylon sling 2 25 t crane 1
shown below.
Lever block 1.5 t 1
Large hammer 1
Others
45
Assembly procedure
Installation of arm assembly (2/2)
B-8
(4) Remove lock plate (2) of arm cylinder top pin (1) fixed to the arm and pull out top pin (1).
(Arm cylinder top pin: 23 kg)
(5) Start the engine, run at low idle, extend the arm cylinder rod slowly, and align the position of the hole.
When doing this, raise the arm cylinder with a crane and operate the arm cylinder at the same time to align the
position.
(6) Insert shims (4) on both sides and push in arm cylinder top pin (1).
a Inside of pin hole and bushing of arm cylinder bushing: Apply LM-P (Only 1st time)
(7) Install lock plate (2).
a Operate the cylinder slowly. Do not operate it quickly and do not bring it to the stroke end. Since air gathers
inside the cylinder at the first time, it may not move for aver 10 seconds, but do not move the lever to the
full stroke.
a When installing the arm, extreme caution should be exercised so that the bucket cylinder rod does not jump
out.
a Check that the pin lock bolt is not loosened but tightened and check its torque.

1 208-70-61220 1
2 205-70-66580 1
3 01024-81235 2
4 208-70-71651 2
a For installation of the grease supply hoses, Name Q’ty Name Q’ty
see Step B-11 "Connection of grease supply Nylon sling 1 25 t crane 1
piping of work equipment".
Large hammer 1
a When pushing in the pin, take care not to break
the dust seal installed to the cylinder boss.
Others
46
Assembly procedure
Installation of bucket cylinder hoses between
B-9 boom and bucket cylinder (1/2)
(1) Remove the tube oil plug on the bucket cylinder side on the left side of the arm, install new O-ring (2), and
connect bucket cylinder hose (1).
(2) Remove the tube oil plug on the machine side, install new O-ring (2), and connect bucket cylinder hose (1).
a Reuse the oil stop parts as the split flange, bolts, etc.
a Bleed air from the bucket cylinder. For details, see B-14 "Bleeding air from work equipment circuit".
a Check that the split flange is not loosened but tightened.
a Check that each O-ring is fitted, has not come off, and is not caught.
PART A
Installation of hose and O-ring

1 207-62-54680 1
2 07000-13032 2
No. Already installed to Q’ty
3 07371-31049 4
4 07375-21035 8
1. Keep the oil plugs used for component so that Name Q’ty Name Q’ty
they can be reused. Oil container 2
2. When installing the hose take extreme care
not to catch the O-ring. Socket 14 mm width across flats 1
3. When installing the hoses, take extreme care
not to twist them. Extension L150 1
(Tighten from the 90° adapter to prevent
twisting.) Small-sized impact wrench 1
4. While installing the hose, take extreme care
not to allow dirt in the circuit.
Others
47
Assembly procedure
Installation of bucket cylinder hoses between
B-9 boom and bucket cylinder (2/2)
(3) Similarly, connect bucket cylinder hose (1) on the right side of the arm.
PART B

1 207-62-54680 1
2 07000-13032 2
No. Already installed to Q’ty
3 07371-31049 4
4 07375-21035 8

1. Keep the oil plugs used for component so that
they can be reused. Oil container 2
2. When installing the hose take extreme care
not to catch the O-ring. Socket 14 mm width across flats 1
3. When installing the hoses, take extreme care
not to twist them. Extension L150 1
(Tighten from the 90° adapter to prevent
twisting.) Small-sized impact wrench 1
4. While installing the hose, take extreme care Ring wrench 14 mm width across
not to allow dirt in the circuit. 1
flats
Others
48
Assembly procedure
Installation of bucket assembly (1/3)
B-10
[Preparation for installation]

1. Remove the stoppers of the bucket-arm connecting pin (fixed to the arm) and bucket-link connecting pin (fixed
to the link), and remove those pins.
2. Lightly install bushing (1) to the boss on the bucket side, and install O-rings (2) to the places shown below.
a Apply LM-P (1st time only) to the inside surface of the bushing (apply lithium grease at the 2nd time and
after).
㪉㪈
O-ring position
[Installation]
3. Run the engine at low idle and operate the boom cylinder and arm cylinder slowly to set the holes for the bucket
and arm connecting pin.
a Weight of bucket assembly: For the weight, see the packing style table for transportation.
4. Install the arm-bucket connecting pin and the lock bolt and nut for the pin, without inserting shim.

1 208-70-34230 1
2 208-70-33181 2

Nylon sling 1 25t crane 1
Sledge hammer 1
Spanner, width across flats: 36 mm 1
Ring spanner, width across flats: 36 mm 1
Large-sized impact wrench 1
Torque wrench: 85 kgm 1
Others
49
Assembly procedure
Installation of bucket (2/3)
B-10
[Adjustment of shim]
5. Lightly tighten the stopper bolt (M24), measure clearance "a", and then decide the number of shims so that
their total thickness is the measured value +0.5 to +1.0 mm.
a Measure when there is no clearance on both sides of the arm end.
O-ring position
Clearance "a"
6. Install shims (1) and (2).
7. Lightly tighten the stopper bolt (M24), check clearance "b" between the arm and bushing is 0.5 to 1.0 mm all
round, and then install the O-rings to the correct positions (both sides of arm end).
O-ring
Correct position of O-ring
Clearance "b"
(0.5 to 1.0 mm)
1 208-70-34250 18
8. Install lock bolt. 2 208-70-34260 4

Sledge hammer 1
When tightening, adjust the clearance
between the double nut and stopper to 0.5 to
1.5 mm. (Clearance marked with *)
Others
50
Assembly procedure
Installation of bucket (3/3)
B-10
[Installation of link]
9. Fit O-ring (1) to prevent entry of soil and sand.
10. While operating the bucket cylinder, align the holes for the bucket-link connecting pin.
a Operate the cylinder slowly. Do not operate it quickly or to the stroke end. In the first operation, there is an
air in the cylinder and the cylinder may not move for the first 10 seconds. In such case, do not operate the
control lever to the end of its stroke.
11. Push in the link-bucket connecting pin, install O-rings (1) to the correct positions to prevent entry of dirt, and
then install the pin stopper.
Correct position of O-ring

1 207-70-33181 2

Sledge hammer 1
When tightening, adjust the clearance
between the double nut and stopper to 0.5 to
1.5 mm. (Clearance marked with *)
Others
51
Assembly procedure
Connection of work equipment grease piping (1/2)
B-11
(1) Remove the oil stopper plug at the cylinder end and the oil stopper plug at the hose nipple end, remove the
nipple from the hose, then assemble the boom cylinder greasing hoses (2 places) at porting (a) to the cylinder
end, and connect.
(2) Remove the oil stopper plug at the cylinder end and the oil stopper plug at the hose elbow end, remove the
elbow from the hose, then assemble the arm cylinder bottom greasing hose at porting (b) to the cylinder end,
and connect.
(3) Remove the oil stopper plug at the cylinder end and the oil stopper plug at the hose elbow end, remove the
elbow from the hose, then assemble the arm cylinder top greasing hose at porting (c) to the cylinder end, and
connect.
Tightening torque of hose

5.9 to 11.8 Nm (0.6 to 1.2 kgm)
(2places)

1 205-70-51390 2
a After installing the boom and boom cylinder, Name Q’ty Name Q’ty
supply grease to parts (a) and (b), and then in- Spanner 19 mm width across flats 2
stall the arm.
a After installing the arm, supply grease to part
(c), and then install the bucket.
Others
52
Assembly procedure
Connection of work equipment grease piping (2/2)
B-11
Tightening torque of hose

5.9 to 11.8 Nm (0.6 to 1.2 kgm)
PART
PART No. Loose-supply items Q’ty

1 205-70-51390 1
2 205-70-51380 1
3 208-70-65770 1

Spanner 19 mm width across flats 2
Others
53
Assembly procedure
Connection of work equipment wiring (1/2)
B-12
(1) Install working lamp (1) and bracket (2).

a Working lamp nut tighteing torque: 17.6 to 19.6 Nm (1.8 to 2.0 kgm)
(2) Connect connector (a) (CN-L01) of the working lamp wire to the body wiring harness.

1 20Y-06-43230 1
2 20Y-06-21551 1
3 01010-81430 1
PART A 4 01643-31445 1
5 08193-20012 1
6 01024-81220 1

Spanner 22 mm width across flats 1
Others
54
Assembly procedure
Connection of work equipment wiring (2/2)
B-12
(3) Connect connector (b) (CN-A13) of the boom wiring harness to the body wiring harness.
a Pass the wiring under the grease tube.
PART B

1 04434-51012 1
2 01024-81225 1

Others
55
Assembly procedure
Greasing after completion of work equipment
B-13
(1) Supply grease to each part.

Use grease LM-G.
1) Boom cylinder foot pin (2 places)

2) Boom foot pin (2 places)
3) Arm and link connecting pin (1 place)
4) Arm and bucket connecting pin (1 place)
5) Link connecting pin (2 places)
6) Bucket cylinder rod end (1 place)
7) Bucket and link connecting pin (1 place)
8) Boom cylinder rod end (2 places)
9) Arm cylinder foot pin (1 place)
10)Boom and arm connecting pin (1 place)
11)Arm cylinder rod end (1 place)
12)Bucket cylinder foot pin (1 place)
Note 1 : Slowly move the boom up and down 3 to 4 times, and then supply LM-G through the fittings.
Note 2 : When assembly, take care extremely that dirt, rust, flaw, etc. will not cause trouble.
Be sure to perform Notes 1 which are important for prevention of galling of the pins.

Grease pump 1
Others
56
Assembly procedure
Bleeding air from work equipment circuit
B-14
After assembling the work equipment piping, bleed the air from it.
(1) Run the engine at low idle.
(2) Move each clinder to about 100 mm before each stroke end 4 - 5 times.
(3) Keeping the engine speed at low idle, move each cylinder from the point of 100 mm before the stroke end to
the stroke end very slowly (taking at least 10 seconds), and then keep the work equipment control lever at the
stroke end for 3 minutes.
[Bleed the air from the boom cylinder, arm cylinder, and bucket cylinder at the extraction stroke end.]
aThe cylinder may not start for more than 10 seconds at first because of the much air in the circuit. Do not
move the lever to the stroke end at this time.
aIf the engine speed is heightened or each cylinder is moved to the stroke end from the first, the piston packing
may be damaged by the air in the cylinder.
aEach time air is bled from each cylinder, retract the cylinder to the stroke end and check the sight gauge of
the hydraulic tank. If the oil level is below L-level, add hydraulic oil through the oil filler port.
a Before operating the cylinder, check that the Name Q’ty Name Q’ty
flushing filter is installed (to capture dirt in the
circuit).
a After the assembly work is completed, perform
the final check of the hydraulic tank oil level re-
ferring to the Assembly procedure M-5 "In-
spection of oil level in hydraulic tank and refill".
Others
57
C. INCREASING AND DECREASING OF TRACK FRAME GAUGE,
ASSEMBLING OF COUNTERWEIGHT
59
Assembly procedure
Increasing and decreasing of track frame gauge (1/6)
C-1
Increasing of track frame gauge (1/3)
(1) Remove front and rear center frame mounting bolts (1) and colors (2) on the side to be extended. (4
pieces each at the front and rear)
(2) Swing the upper structure to a right angle to crawler frame (3) to be extended, connect bucket (4) and
crawler frame (3) to be extended by chain block (5), and raise crawler frame (3) by using the work
equipment.
(two pieces at both ends of crawler frame)
Tooth side Crawler side
a Limit the raising height (H) of the crawler frame Name Q’ty Name Q’ty
to 20 mm. ø10 × 3,000 mm wire 2
(If the crawler frame is raised too high, the
stopper bolt will be pried and bent.) ø20 × 5,000 mm wire 2
a When pulling the crawler frames with the lever
blocks, pull them so that the wires will be as
level as possible. Lever block 3 ton 2
a When decreasing the gauge, see C-1 De-
creasing of track frame gauge (4/6) to (6/6).
Others
60
Assembly procedure
C-1
(3) Extend crawler frame (3) until it reaches stopper (6), lower the machine slowly to the ground, and
install bolts (1) and collars (2) (9 pieces each at the front and rear).
• Tightening torque: 1,520 to 1,910 Nm (155 to 195 kgm)
a Install the bolts of the four positions marked with first, since other bolts are installed on
the base of those bolts.

1 208-30-12130 20
(4) Work on the crawler frame on the opposite side similarly. 2 208-30-41390 20

Torque wrench (420 kgm) 1
Others
61
Assembly procedure
C-1
Wooden block
a When tightening the bolts, raise the track shoe by the level portion with jacks or wooden blocks as
shown above to secure a space for the tightening work.
• Do not remove the shoe during the above Name Q’ty Name Q’ty
work. 5 t Hydraulic jack 1
(For securing the tightening torque of the
shoe bolts.)
Torque wrench 420 kgm 1
• Each collar must not ride over the spot facing. Wooden block 400 × 200 mm 1
Others
62
Assembly procedure
C-1
Decreasing of track frame gauge (1/3)
(1) Remove front and rear center frame mounting bolts (1) on the side to be retracted. (9 pieces each
at the front and rear)
(2) Swing the upper structure to a right angle to crawler frame (2) to be retracted, connect right and
left crawler frames (2) and (3) by chain block (4), and raise crawler frame (2) by using the work
equipment and pull it with chain block (4) to decrease the gauge.
Limit the raising height (H) of the crawler Name Q’ty Name Q’ty
frame to 50 mm.
(If the crawler frame is raised too high, the
stopper bolt will be pried and bent.)
Others
63
Assembly procedure
C-1
(3) Retract crawler frame (2) until it reaches stopper (5), lower the machine slowly to the ground, and
install bolts (1) and collars (2) (4 pieces each at the front and rear).
• Tightening torque: 1,520 to 1,910 Nm (155 to 195 kgm)
Guide plate
(4) Work on the crawler frame on the opposite side similarly.
a When decreasing the gauge, loosen the track. Name Q’ty Name Q’ty
(Loosening quantity is 30 to 50 mm. See
Step C-4, "Adjustment of track tension".)
After increasing the gauge, tense the
track.
(To prevent wear of the guide plate.)
a When decreasing the gauge, do not travel the
machine for a long time.
Others
64
Assembly procedure
C-1
Wooden block
a When tightening the bolts, raise the track shoe by the level portion with jacks or wooden blocks as
shown above to secure a space for the tightening work.
• Do not remove the shoe during the above work. Name Q’ty Name Q’ty
(For securing the tightening torque of the
shoe bolts.)
• Each collar must not ride over the spot facing.
Others
65
Assembly procedure
Installation of steps
C-2
• Using bolts and washers (3) and (4), install steps (1) and (2) to the 4 places at the front, rear, right, and left
of the track frame.
a When assembling, eliminate

clearance in steps (1) and (2).
(All places)

1 208-30-41611 4
2 208-30-41621 4
3 01010-81640 32
4 01643-31645 32
a If any clearance is made, the bolts are broken Name Q’ty Name Q’ty
easily when the lower step is deformed. Socket 24 mm width across flats 1
Others
66
Assembly procedure
Installation of travel piping covers (1/4)
C-3
(1) Installation of left travel piping cover

1 208-30-41311 1
2 01643-31645 3
3 01010-81635 3
4 208-30-75351 1
5 418-18-31160 4
6 01010-81635 4
a Install all the covers (both right and left ones) Name Q’ty Name Q’ty
temporarily and adjust the clearance and level Socket 24 mm width across flats 1
difference, and then tighten them permanent-
ly.
Others
67
Assembly procedure
C-3
(2) Installation of left travel piping cover

1 208-30-75332 1
2 01643-31645 2
3 01010-81640 2
4 208-30-58230 1
5 01643-31645 4
6 01010-81635 4
a Clearances "a" and "b" in the cover must be Name Q’ty Name Q’ty
the same on the right and left sides. Socket 24 mm width across flats 1
Others
68
Assembly procedure
C-3
(3) Installation of right travel piping cover

1 208-30-41321 1
2 01643-31645 3
3 01010-81635 3
4 208-30-75361 1
5 418-18-31160 4
6 01010-81635 4

Others
69
Assembly procedure
C-3
(4) Installation of right travel piping cover

1 208-30-75342 1
2 01643-31645 2
3 01010-81640 2
4 208-30-58230 1
5 01643-31645 4
6 01010-81635 4
a Clearances "a" and "b" in the cover must be Name Q’ty Name Q’ty
the same on the right and left sides. Socket 24 mm width across flats 1
Others
70
Assembly procedure
Adjustment of track tension (1/3)
C-4
Testing and adjusting track tension
k Warning
This work must be done by 2 persons. The operator

shall move the machine according to the signs from the
worker.
Since the wear condition of the pins and bushings of the

undercarriage varies with the working condition and soil
type, check the track tension occasionally and keep it at
the standard.
Test and adjust the track tension on a level and hard
place.
Testing
(1) Stop the machine on a level and firm place.

(2) Place a rectangular bar (3) which is longer than
the distance between idler (1) and carrier roller
(2) on the track.
(3) Measure the maximum slack between the top of
the track and the underside of the rectangular
bar.
• Standard slack
If slack "a" is 16 to 34 mm, it is normal.
a When delivered, the slack is set to 30 to 50 mm

so that the gauge can be extended easily.

Others
71
Assembly procedure
C-4
If the track tension is out of the standard, adjust it according to the following procedure.
Adjusting
k Warning
Do not loosen the plug more than 1 turn. If it is loosened

more, it may jump out because of the internal high-pres-
sure grease.
At this time, do not loosen any part other than the plug.
Do not direct your face in the installed direction of the
plug.
Increasing track tension

(1) Add grease through plug (1) with the grease
pump.
(2) Move the machine forward and backward to
check that the track tension is proper.
(3) Check the track tension again. If it is not proper,
adjust it again.
(4) You may supply grease until (S) is 0 mm. If the
tension is still low, the pin and bushing are worn
excessively. In this case, turn over or replace the
pin and bushing. Consult your Komatsu distribu-
tor.

Grease pump 1
Others
72
Assembly procedure
C-4
Decreasing track tension
k Warning
It is very dangerous to discharge grease by a method

other than the following procedure.
(1) Loosen plug (1) slowly to discharge the grease.

(2) Do not loosen the plug (1) more than 1 turn.
(3) If the grease does not come out, move the ma-
chine back and forward a little.
(4) Tighten plug (1).
(5) Move the machine forward and backward to
check that the track tension is proper.
(6) Check the track tension again. If it is not proper,
adjust it again.

Extension L150 1
Others
73
Assembly procedure
Sticking sheet to counterweight
C-5
• Stick the seats to the front side of the counterweight as shown below.
When sticking seats (1), (2), (3), (4), and (5), direct the faces having no black cover down.
Direct the faces having no black

cover down.
1 208-46-41711 1
2 208-46-41721 1
3 208-46-41731 1
4 208-46-41741 1
5 208-46-41761 1
Remove all oil and rust from the surface Name Q’ty Name Q’ty
where the sheet is to be stuck.
Others
74
Assembly procedure
Installation of camera (1/6)
C-6
(1) Pass wiring harness (1) through the hole of the counterweight.

1 208-06-24230 1

Others
75
Assembly procedure
C-6
(2) Connect connector (CN-A45) as shown below and install camera A (1) with bolts (2).
Face A
Match line of camera with angle of bracket
Top of camera must be in parallel with face A

1 Camera A. 1
2 01024-81025 2

Others
76
Assembly procedure
C-6
(4) Install cover (1) as shown below.
Adjust shim (2) so that ※ marked

clearance difference will be 2 mm
max. at points a, b, and c.

1 2A5-06-11821 1
2 2A5-06-12240 3
3 01024-80616 2

Others
77
Assembly procedure
C-6
(5) Install cover (1) as shown below.

1 207-06-76451 1

Others
78
Assembly procedure
C-6
(6) Remove the double-sided adhesive tape and stick seat (1) as shown below.
Then, connect the clips on the wiring harness side and counterweight side (6 places).
Install clips (6 places)

5 places at ※ : Counterweight
1 place at u: Machine frame

1 2A5-06-11860 1

Others
79
Assembly procedure
C-6
After installing, watch the monitor screen and check "how the counterweight is displayed".
"Monitor screen"
"If dimension L is out of the following range, adjust the installed angle of
the camera"
L: Must be in range from 4.5 to 13 mm Counterweight

Others
80
Assembly procedure
Installation of counterweight (1/3)
C-7
(1) Sling counterweight assembly (1) and install it to the machine.

(2) Install by using mounting bolts (2) (4 pieces) and washers (3) (4 pieces).
Lightly tighten the bolts with a hand wrench or a small-sized impact
wrench until each installation face of the counterweight is seated,
and then tighten them to the specified torque.
a Check that the bolts are not loosened but tightened and check their torque.
Weight of counterweight assembly : 9,570 kg
Tightening torque:
3430 to 4212 Nm
(350 to 430 kgm)
Since these are important bolts, tighten them to

the center value of the specified torque range.
Center value of tightening torque:
a Parts (4) are shims for adjusting 3,820 Nm (390 kgm)
clearance and level difference
208-46-52260: 1 mm thick 2 208-46-41610 4
208-46-52270: 0.5mm thick 3 01643-34212 4
208-46-52260 4
4
208-46-52270 4

a Do not insert any shim basically for adjusting Name Q’ty Name Q’ty
clearance or level difference.
If adjustment is necessary observe the follow- ø30 × 3,000 mm wire 2 25 t crane 1
ing.
a) Adjust by inserting a shim only in the Shackle SD32 2
backward and forward directions.
Example: No shim in both front holes and Socket 65 mm width across flats 1
shims 1 mm thick in both rear holes.
b) Limit the adjustment quantity with shim to 2 Large-sized impact wrench 1
mm.
Torque wrench 420 kgm 1
a For adjustment after assembling the counter-
weight, see 3/3.
a Dimension of hanging hole of counterweight

ø42 mm
Others
81
Assembly procedure
C-7
(3) When installing the counterweight to the machine, take care not to catch the wiring harness of the rear view
monitoring camera.
After installing, install harness clips (one place at u) and connect connector (CN-A40).
a Take care not to catch

wiring harness of rear
view monitoring camera
䇭䇭㩷
䇭䇭䇭䇭䂹
䇭䇭䇭䇭
䇭䇭䇭䇭
Connector (CN-A40)

a When installing, do not enter between the
revolving frame and counterweight but
open the left door and check that the wir-
ing is not caught.
Others
82
Assembly procedure
C-7
(4) Adjustment method of assembled counterweight
a) Clearance to revolving frame must be 10 ± 5 mm on both right and left sides.

b) Level difference from revolving frame must be 5mm or less on both right and left sides.
c) Clearance to exterior door must be 10 ± 5 mm on both right and left sides.
d) Level difference from exterior door must be 8 ± 4mm or less on both right and left sides.
e) Level difference from top of exterior door must be 5mm or less on both right and left sides.
Level difference: 8 ± 4 mm
Counterweight (Difference between points T and S: 0 to 4 mm)
Level difference "e":
0 to 5 mm
Left door Clearance "c": 10 ± 5 mm

(Difference between points T and S: 0 to 3 mm)
Left door side
Counterweight
Level difference "b":
Level difference "d": 0 to 5 mm
8 ± 4mm
Counterweight Right door
Clearance "a": 10 ± 5 mm
Right door side
Counterweight
Level difference "b": 0 to 5 mm

Others
83
M. PROCEDURE FOR INSPECTION AND MAINTENANCE AFTER
COMPLETION OF ASSEMBLY
85
Assembly procedure
Replacement of return filter
M-1 (Standard filter to flushing filter)
Replace the hydraulic oil return filter element, valve and strainer of standard items
with hydraulic oil flushing element (1) and plate (2).
a When replacing the element, take out the ele-

ment slowly so that refuses adhered to the ele-
ment do not fall inside. Also, take out refuses by
hand from the case
Replace the relief valve with this

Replacement
plate only at the flushing time.
Special element for flushing,

Absolute filter mesh size: 6 m

1 208-60-71170 1
2 21T-60-13730 1
a Store the removed standard element Name Q’ty Name Q’ty

(208-60-71123), strainer (07069-25400) and
valve (208-60-71160) in order because they
are used again after flushing.
a Replace before starting the assembly work.
(To capture dirt during the hose connecting
work and in the work equipment circuit)
Others
86
Assembly procedure
Flushing of hydraulic circuit (1/2)
M-2
After completion of assembling flush the hydrau

lic circuit as follows:
a Run the engine at low idle (at the minimum throttle)

with the levers in neutral for 15 minutes, and then
perform the following.
(1) Flushing of Work Equipment Pipes

Extend and contract each cylinder for several
minutes without reaching them to the stroke end.
(a) Extension and contraction of bucket cylinder

for 5 minutes
(b) Extension and contraction of arm cylinder for 5

minutes.
(c) Extension and contraction of boom cylinder for

5 minutes
Full operation may damage the filter element Name Q’ty Name Q’ty
since the relief valve of the filter is closed.
Others
87
Assembly procedure
Flushing of hydraulic circuit (2/2)
M-2
(2) Flushing of Swing Circult

Right swing and left swing for 3 minutes each
(3) Flushing of Travel Circuit

Press the ground with the work equipment
as illustrated here to raise one side of the
machine, and operate the travel lever as folows:
• Forward travel and backward travel to the right

For 3 minutes each
• Forward travel and backward travel to the left

For 3 minutes each
(4) Check
After finishing flushing, replace the flushing filter with the standard one according to "Replacement of return
filter (2/2)".
At this time, check that the dirt captured in the flushing element has no problem. If the dirt seems to have
problem, consult your Komatsu distributor.

Others
88
Assembly procedure
M-3 (Flushing filter to standard filter) (1/2)
Reassemble hydraulic oil return filter element (1), strainer (2) and valve (3) which you have removed in the previ-
ous step.
a When replacing the element, take out the ele-

ment slowly so that refuses adhered to the ele-
ment do not fall inside. Also, take out refuses by
hand from the case
Replacement
Valve (3)
Valve (2)
Standard element (1)

Others
89
Assembly procedure
M-3 (Flushing filter to standard filter) (2/2)
State of inserted element
Element
Fig. 1 Correct state Fig. 2 Incorrect state
a Do not insert the element so that it stands on the step at the bottom of the case as shown in Fig.
2.When the filter case is filled with oil, it is difficult to check if the element is inserted correctly,
so turn the element by hand after inserting it in the case. When it turns smoothly, it is considered
to be inserted correctly.

Others
90
Assembly procedure
Check of oil/coolant level at each part (1/2)
M-4
a For details of the notes (Note 1, 2, 3, 4, 5, 6) in the table, see the "Operation and Maintenance Manual".
For details of the recommended genuine oil, see the "Operation and Maintenance Manual", too.
91
Assembly procedure
Check of oil/coolant level at each part (2/2)
M-4
Final
Swing drive case
Engine Damper Hydraulic Cooling AdBlue®
machin- (Each of Fuel tank
oil pan case oil system system /DEF
ery case right and
left)
Specified capac-
42 20 11 1.6 472 44 650 60
ity (l)
Refill capacity
38 20 11 1.6 248 44 – –
(l)
Decide the mixing proportion of the coolant to the water according to the past minimum temperature and the
following mixing proportion table.
Actually, set the proportion for a temperature about 10 °C lower than the past minimum temperature.
Mixing proportion of water and coolant

Min. temperature
(°C) Above
-15 -20 -25 -30 -35 -40
Quantity -10
(l)
Coolant 13.2 15.8 18.0 20.2 22.0 23.8 25.5
Water 30.8 28.2 26.0 23.8 22.0 20.2 18.5
k Waring
Coolant is flammable. So keep it away from
open flame.
Use city water to dilute.
Adjust the control proportion by using an antifreeze concentration meter.
k Waring
When removing the drain plug, take care that
the coolant and water mixture will not be
splashed over you.
• When the machine is delivered, it is filled with Name Q’ty Name Q’ty
Supercoolant (blue) containing no amine. Do
not add coolant of different type.
Others
92
Assembly procedure
Inspection of oil level in hydraulic tank and refill (1/2)
M-5
Inspection of oil level in hydraulic tank and refill
k Warning
• When removing the cap from the oil filler port,
turn it slowly to relieve the internal pressure so
that the oil will not burst out.
(1) If the machine is not in the state illustrated here,

start the engine, rotate it at a low speed, reduce
the arm and the bucket cylinder, lower the boom
slowly so that the bucket teeth touch the
ground, and then stop the engine.
(2) Set the start switch to the ON position with in 5
to 6 seconds after stopping the engine and set
each control lever (work equipment and travel)
to the full stroke in each direction to relieve in-
ternal pressure.
(3) Open the door on the left side of the machine
and check the sight gauge (G). When the oil lev-
el is between the H and L lines, the level is ap-
propriate.
(4) When the oil level is below the L Iine, supply oil
through the oil filter port (F).
For applicable oil, "Check of oil/coolant level at

each part M-4 ".
Notice:
Do not supply oil, beyond the H line, but the hydrau-
lic circuit may be damaged or oil may burst out.

Others
93
Assembly procedure
Inspection of oil level in hydraulic tank and refill(2/2)
M-5
k Warning
• If the oil level is higher than level H, stop

the engine, wait until the hydraulic oil
cools down, and then remove under-
cover (1) or (2) and drain excessive oil
through drain plug (P) or (A).After drain-
ing the oil, tighten the drain plug and
install the undercover.
Supplementary Explanation:
Since the oil level changes as the oil temperature

changes, check the oil level noting the following
as guides:
• The oil level shall be around the L level before

operation (when the oil temperature ranges
from 10 to 30°C).
• The oil level shall be around the H level during
normal operation (when the oil temperature
ranges from 50 to 80°C).

Others
94
Assembly procedure
Parts to be touched up after field assembly
M-6
After assembling the large-sized hydraulic excavator in the field, touch up the following parts.
(1) Underside of front and rear of boom (2) Underside of arm
(3) Underside of counterweight (4) Underside of bucket
(5) Track frame (Flaws made during increasing/

decreasing of gauge, unpainted parts)
(Right and left sides, 4 places in total)
When the machine is used on the seashore, etc. where it is rusted easily, touch up the following
parts, too.
Unpainted parts of machined surfaces of flanges after installing piping Grease tubes
Metallic hose bands, etc.
Use rust-prevent clear paint for touching up the machined surfaces, etc.
(Recommended brand: KOMATSU genuine rust-preventive clear paint)

Others
95
Assembly procedure
Error code
M-7
Turn the key switch to the ON position and check that no error code is displayed on the monitor.
If any error code is displayed, consult your Komatsu distributor.
96
Arm cylinder lock plate

Boom top lock plate
Tightening torque: M12 98 to 123 Nm {10 to 12.5 kgm}
M20 455 to 565 Nm {46.5 to 58 kgm}
Bolt size: M12 Bolt size: M20

No. Torque No. Torque
1 3
2 4
97
Boom foot lock plate

Tightening torque: M20 455 to 565 Nm {46.5 to 58 kgm}
No. Torque
1
2
98
Boom cylinder bottom lock plate

Tightening torque: M12 98 to 123 Nm {10 to 12.5 kgm}
Right side of chassis Left side of chassis

1 3
2 4
99
Counterweight mounting bolt

Tightening torque: 3,430 to 4,212 Nm {350 to 430 kgm}
Since these are important bolts, tighten them to the center value of the specified torque range.
Center value of tightening torque: 3,820 Nm (390 kgm)
No. Torque
1
2
3
4
100
Center frame x crawler frame

Tightening torque: 1,520 to 1,910 Nm {155 to 195 kgm}
Front of chassis
Left of chassis Right of chassis
Rear of chassis
Right side of chassis Left side of chassis

1 19
2 20
3 21
4 22
5 23
6 24
7 25
8 26
9 27
10 28
11 29
12 30
13 31
14 32
15 33
16 34
17 35
18 36
101
4/13
Category
Revision
Local After
Check item assembly hours of Judgement standard
time operation
Monitor display
1. Check of monitor function
When the starting switch is turned ON, the gauges,
CHECK items, and all display items on the monitor should
light up. At the same the alarm buzzer should sound.
2. Check of gauges and CHECK items
When starting switch is turned to ON (all lamps on), all As per left
display lamps should go out after approx. 3 sec.
For another 2 seconds, only the gauges are displayed,
and the CHECK and monitor items disappear.
3. Check of monitor items
After starting the engine, the caution lamps should not
light up and the alarm buzzer should not sound when the
engine speed is low idling – high idling.
There should be no scratches or misting
Operation of service meter of the lens or variation in operation.
MONITOR
Ordinal display
(1) Wiper switch
(2) Buzzer cancel switch
(3) Auto-deceleration switch
(4) Service meter, Clock
(5) ECO gauge
(6) Camera direction monitor
(7) Hydraulic oil temperature gauge
(8) Hydraulic oil temperature monitor
(9) Engine coolant temperature gauge
(10) Engine coolant temperature monitor
(11) Fuel gauge
Check monitor
(12) Fuel level monitor

(13) Ad/Blue/DEF level gauge
(14) Ad/Blue/DEF level monitor
(15) Fuel consumption gauge
(16) Working mode selector switch
(17) Travel speed selector switch
(18) Window washer switch
(19) Air conditioner control switches
(20) Seatbelt fixing monitor
(21) Engine stop monitor
(22) Lock lever monitor
Display of meter only (23) KDPF regeneration monitor
(24) KDPF regeneration stop monitor
(25) Message monitor
(26) Air conditioner monitor
(27) Wiper monitor
(28) Swing lock monitor
(29) Engine pre-heating monitor or
One-touch power max. monitor
(30) Auto-deceleration monitor
(31) Working mode monitor
(32) Travel speed monitor
(33) Radiator coolant level monitor
(34) Air cleaner clogging monitor
(35) Engine oil level monitor
(36) Charge level monitor
(37) Ad/Blue/DEF system monitor
(38) Engine oil pressure monitor
(39) Function switches (F1 to F6)
(40) Maintenance interval monitor
5/13
Category
Revision
Local After
time operation
Check of switches, control levers
(1) Radio (14) Machine push-up switch

(2) Lock lever (15) Ceiling window wiper switch (if equipped)
(3) Left work equipment control lever (16) Revolving warning lamp switch (if equipped)
(4) One-touch power max. switch (17) Attachment control pedal (if equipped)
(5) Travel pedals (18) Attachment control pedal (if equipped)
(6) Travel levers (19) Cigarette lighter
(7) Horn switch (20) Room lamp switch
(8) Machine monitor (21) Heated seat switch (if equipped)
(9) Right work equipment control lever (22) Engine shut down secondary switch
(10) Starting switch (23) Secondary pump drive switch
(11) Fuel control dial (24) Swing brake cancel switch
(12) Lamp switch (25) Lock lever auto release switch
(13) Swing lock switch
Operation of horn switch If the switch is pushed, the horn sounds.
Operation of lock lever Push down the lever to apply the lock.
Engine can be started but all work
equipment control levers do not move.
Push up the lever to release the lock.
Engine cannot be started but all work
equipment levers move.
Operation of fuel control dial MAX: Full speed
MIN: Low idle
6/13
Category
Revision
Local After
time operation
Operation of working mode selector switch Lighting of P: For heavy load work
(ATT/P)
Lighting of E: For economical work
(ATT/E)
Lighting of L: For inching operation
Lighting of B: For breaker work
Monitor display changes, synchronizing
with switch
Full throttle speed of engine changes
Operation of auto-deceleration switch ON lights up: Auto-deceleration is

actuated.
OFF: Auto-deceleration is
canceled.
Each time the switch is pressed, the

auto-deceleration is actuated or
canceled.
Operation of travel speed switch La lights up: Low speed travel
Mi lights up: Middle speed travel
Hi lights up: High speed travel
When the engine is started, the travel

speed is automatically set to Lo.

Operation of wiper switch OFF: Wiper stops
ON lights up: Wiper moves continuously
INT lights up: Wiper moves intermittently
Each time switch is pressed, monitor
display changes and can be selected.
Operation of window washer switch Window washer fluid is sprayed out.
Operation of cigarette lighter This is used to light cigarettes. To use,

push the lighter in. After a few seconds
it will spring back.
Operation of lamp switch This switch is used to turn on the front
lamps working lamps, additional lamp at
the top front of the cab, and monitor
lighting.
Operation of swing lock switch ON position (actuated):
The swing lock is always applied,
and the upper structure will not
swing even if the swing is
operated. In this condition, the
swing lock lamp lights up.
OFF position (canceled):
Swing operation is possible. Swing
lock monitor goes off.
Operation of machine push-up switch Low pressure setting:
The boom thrust force is weak.
High pressure setting:
The boom thrust force becomes
more powerful.
Operation of room lamp switch ON position: Room lamp lights up.
Operation of secondary pump drive switch Normal state:

Switch is in "LOWER" position
While monitor is indicating "L03 pump control error", if switch If switch is set to "UPPER" position,
is in "UP" position, emergency pump can be driven alarm buzzer sounds.
7/13
Category
Revision
Local After
time operation
Operation of lock lever auto lock cancel switch When normal: Switch is in "Lower"
position.
When this switch is set in "Upper" position, the lock lever auto
lock function is disabled. If the switch is set to "Upper" position,
When the lock lever is released while the control lever or the lock lever lock switch cancel monitor
pedal is operated, the work equipment or machine moves. lighting up.
Operation of swing brake cancel switch Normal state:
Switch is in "LOWER" position
While monitor is indicating "L03 swing brake error", if switch
is in "UP" position, brake is cancelled and upper structure can If switch is set to "UPPER" position,
swing. alarm buzzer sounds and swing
However, swing brake is kept cancelled. lock symbol flashes
Operation of alarm buzzer stop switch This is used to stop alarm buzzer if it
sounds to warn of an abnormality during
operation.
ON: Lower wiper moves.
Operation of lower wiper switch (option) OFF: Lower wiper stops.
Operation of travel levers FORWARD:
The lever is pushed forward.
(The pedal is angled forward)
REVERSE:
The lever is pulled back.
(The pedal is angled back)
N (Neutral):
The machine stops.
Operation of left work equipment control lever This lever is used to operate the arm
(with auto-deceleration device) and upper structure.
Arm operation Swing operation
N (Neutral):
When the lever in this position, the
upper structure and the arm will be
retained in the position in which
they stop.
Operation of right work equipment control lever This lever is used to operate the boom
(with auto-deceleratiom device) and bucket.
Boom operation Bucket operation
N (Neutral):
When the lever in this position,
the boom and the bucket will be
retained in the position in which
they stop.
Confirmation of failure history Check there is no abnormality, then
(Both electrical and mechanical) delete abnormality record. When
finishing inspection, check again there is
no abnormality record.
Operation of power max. switch When the switch on the LH work
equipment control lever is pushed, the
digging power increases.
Check function of rotation lamp switch
(option) ON: Rotary lamp lights up
Leakage of AdBlue/DEF from each part There must be none.
(AdBlue/DEF tank, pump, injector piping)
12/13
Note: If the operation or function is defective, measure as necessary. All judgement standard values for speeds are the values in P mode.
Category
Revision
Local After
time operation
1. Engine speed
Low idle speed [ rpm ] 1000 ± 50 rpm
High idle speed [ rpm ] 1930 ± 50rpm
Speed at arm OUT [ rpm ] 1930 ± 100 rpm at P mode
When mode is P and

Speed at arm IN [ rpm ] 1830 ± 100 rpm
swing lock is ON
2. Readiator fan speed
Speed at engine high idle [ rpm ]

speed 1270 ± 50 rpm
When oil temperature is 50 oC and fan
rotation is 100%
3. Oil pressure measurment (measure at pump outlet port)
RAISE 34.8 (+1.47 / -1.18)MPa

Measurement items
{355 (+15 / -12)kg/cm3}

Boom
*37.3 (+1.47 / -1.18)MPa
• Hydraulic oil temperature : Within opera-
tion range {380 (+15 / -12)kg/cm3}
34.8 (+1.47 / -1.18)MPa

Arm
• Engine at high idle {355 (+15 / -12)kg/cm3}
• Working mode: P mode *37.3 (+1.47 / -1.18)MPa

Bucket
{380 (+15 / -12)kg/cm3}
• Hydraulic pump output pressure with all
measurement circuits relieved
30.9 (+1.47 / -2.65)MPa
Swing • Values indside parenthesis :
Hydraulic oil pressure with power max. {315 (+15 / -20)kg/cm3}
switch in ON mode
(reference only) 37.3 (+2.94 / -1.13)MPa
Travel
{380 (+30 / -10)kg/cm3}
• Hydraulic oil temperature: Within opera- 3.24 ± 0.2 MPa
tion range
{33 ± 2 kg/cm3}
Control circuit source • Engine at high idle
pressure
• Self pressure reducing valve output pres-
sure with all control levers in NEUTRAL
position
• Hydraulic oil temper-
ature: Within operat- When all control 4.2 ± 1.0 MPa
ing range levers in NEUTRAL
• Engine at high idle position {42 ± 10 kg/cm3}
• Working mode: P
LS differential pressure mode
• Traveling speed: Hi
When traveling at 2.65 ± 0.1 MPa
• Hydraulic oil pump half stroke
pressure-LS pres- (At idling) {27 ± 1 kg/cm3}
sure
13/13
Category
Revision
Local After
time operation
Measure in
posture at right
4. Hydrauric drift of work equipment
(Bucket load: 3,060 kg, hydraulic oil temperature 50 ± 5°C)
Bucket tooth tip Max. 600 mm/15 minutes

[ mm ]
Note: Measure the hydraulic drift of the following cylinders only if

the hydraulic drift at the bucket tooth tip does not pass the test.
Measure retraction distance of each of following cylinders.
Boom cylinder [ mm ] Max. 29 mm/ minutes
Arm cylinder [ mm ] Max. 100 mm/ minutes
Bucket cylinder [ mm ] Max. 35 mm/ minutes
5. Operation force, travel
Boom  RISE N  LOWER N 15.7 ± 3.9 N 

lever Operating
force     
 (kg)   (kg)  {1.6 ± 0.4 kg}


Stroke: 85 ± 10 mm
RISE LOWER PLAY 
Stroke
[ mm] [ mm] [ mm] Play: Max. 15mm 

Swing
 RIGHT N  LEFT N 
Measurement items
12.7 ± 2.9 N
lever Operating
    
force
 (kg)   (kg)  {1.3 ± 0.3 kg} 

RIGHT LEFT PLAY Stroke: 85 ± 10 mm 
Stroke 

Bucket  CURL N  DUMP N 12.7 ± 2.9 N 
lever Operating
force     
 (kg)   (kg)  {1.3 ± 0.3 kg}


Stroke: 85 ± 10 mm At engine high
CURL DUMP PLAY 
Stroke idling, relief
[ mm] [ mm] [ mm] Play: Max. 15mm 

Arm lever  IN N  OUT N 
15.7 ± 3.9 N
Operating
    
force
 (kg)   (kg)  {1.6 ± 0.4 kg} 

IN OUT PLAY Stroke: 85 ± 10 mm 
Stroke 

Right  FOR– N  RE– N 24.5 ± 5.9 N 
travel Operating
lever force     
 WARD (kg)   VERSE (kg)  {2.5 ± 0.6 kg}


FORWARD REVERSE PLAY Stroke: 115 ± 15 mm 
Stroke

Play: Max. 20mm
[ mm] [ mm] [ mm] 

Left travel  FOR– N  RE– N 24.5 ± 5.9 N 
lever Operating
force     
 WARD (kg)   VERSE (kg)  {2.5 ± 0.6 kg}

FORWARD REVERSE PLAY Stroke: 115 ± 15 mm 
Stroke 
[ mm] [ mm] [ mm] Play: Max. 20mm 

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GEN00126-01

Operator for assembly

Mechanics Sharing of work

A. Assembly of chassis ....................................................................................................... 23

B. Assembling of work equipment ....................................................................................... 33

C. Increasing and decreasing of track frame gauge, assembling of counterweight ............ 59

M. Procedure for inspection and maintenance after completion of assembly ..................... 85

Mounting bolt torque check sheet

3. Preparation and check of protective gear, slings and tools

4. k Check during actual work

Backhoe · Inspection of oil level and

*2 Installation of boom cylinder

*2•*3 Installation of boom

*2•*4 Installation of arm

Greasing of work equipment

Air bleeding (work equipment)

Check of oil and coolant levels

These machines can be divided into three kits for transportation.

(Upper structure + Undercarriage) (Work equipment) (Others)

t Packing Style of Each Kit (Sizes in drawing are given in millimeters.)

(3) Boom cylinder

Weight (kg) 9,570

2 Crane truck 25 ton 1

17 Socket for 4:1 torque 1 each Track frame

33 Shackle SD32 2 Rated load of 6 t for counterweight

39 Hydraulic oil HO56-HE 200 l

43 Cloth 1 bundle 20 kg For cleaning

Part No. of bolt TTTTT-TTTTT

2. The bolt length is dimension (c) in Fig. 1.

a : Bolt thread diameter (Nominal diameter)

Nominal size of thread Width across flats Tightening torque

a For symbols “a” and “b” in the table, see Fig. 1.

Table 4.1 Hydraulic hose of face seal type

Type that uses O-ring

Approx. 10 22 54 – 93 {5.5 – 9.5} 74 {7.5}

Approx. 13 27 84 – 132 {8.5 – 13.5} 103 {10.5}

Approx. 16 32 128 – 186 {13.0 – 19.0} 157 {16.0}

Approx. 20 36 177 – 245 {18.0 – 25.0} 216 {22.0}

Table 4.2 Hydraulic hose of taper seal type

Type that does

Approx. 6 19 34 – 63 {3.5 – 6.5} 44 {4.5}

Approx. 10 24 59 – 98 {6.0 – 10.0} 78 {8.0}

Approx. 13 27 84 – 132 {8.5 – 13.5} 103 {10.5}

Approx. 16 32 128 – 186 {13.0 – 19.0} 157 {16.0}

Approx. 20 36 177 – 245 {18.0 – 25.0} 216 {22.0}

Note: When connecting hose, take care not to twist them.

LT-1A 790-129-9030 150 g Tube • Used to fix rubber gasket, rub-

HOLTS • Heat-resistant sealant for re-

• Feature: Can be used with

Bio grease • Decomposed by bacteria in na-

• Used as paint primer for

• Used as primer for black

For gluing cab glass

Annex 2, Table 1 Using loads of 6 × 24 type rope slings.

Sling angle   = 0°  Z 90° 90° <  Z 120°

tRated load table (WW-1D type)

For USA specifications

No. Loose-supply items Q’ty

Precautions Necessary tools Necessary equipment

• Install grip (1) with bolts (2).

No. Loose-supply items Q’ty

Precautions Necessary tools Necessary equipment

No. Loose-supply items Q’ty

2•3 Installation of boom

2•4 Installation of arm